Container Liner Insertion Using Vacuum Gripping and Overturning
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Solution Overview
Problem
Existing methods for applying removable liners inside paint containers are inefficient and lack scalability for industrial use, hindering the widespread adoption of reusable containers that reduce waste and environmental impact.
Innovation Solution
An automated apparatus that includes a de-stacking device, manipulator, and conveyor system to quickly and efficiently insert and secure removable liners into cylindrical containers, utilizing vacuum gripping elements and expandable membranes to orient and position liners correctly within the containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used to apply liners inside containers, then the process can be performed with simple equipment, but the productivity and efficiency are low
Solution Approach 1:
The apparatus is divided into distinct functional modules: a de-stacking device for removing liners from nested stacks, a manipulator for positioning and inserting liners into containers, and a conveyor system for moving containers. Each module operates independently but coordinates with others, enabling high-speed automated liner application while maintaining manageable system complexity through modular design.
Solution Approach 2:
The de-stacking device automatically separates nested liners without manual intervention by utilizing the liners' own structural properties (flexibility and nesting configuration). The expandable membrane at the liner opening self-expands upon contact with the container, automatically orienting and positioning the liner within the container body, reducing the need for complex positioning mechanisms.
2Productivity
If automated apparatus is used to apply liners, then productivity increases, but the device complexity increases
Solution Approach 1:
The manipulator is designed as a multi-functional device that performs multiple operations: gripping the liner, transporting it to the container, inserting the liner into the container, and releasing it. This consolidation of functions into a single device reduces the number of separate components needed, managing system complexity while maintaining high productivity through coordinated automated operations.
Solution Approach 2:
The apparatus incorporates dynamic elements including the expandable membrane that changes shape upon contact with the container, and the manipulator's movable gripping elements that adapt to the liner's form. These dynamic features enable the system to handle flexible liners efficiently without requiring overly complex rigid positioning mechanisms, balancing automation capability with manageable complexity.
3Loss of time
If liners are manually positioned and secured, then the equipment required is simple, but the time consumption increases
Solution Approach 1:
The de-stacking device performs preliminary actions by automatically separating and pre-positioning liners in readiness for insertion, eliminating manual preparation time. The expandable membrane is pre-configured within the liner to automatically expand upon container contact, pre-planning the liner's final positioned state without requiring separate positioning operations during the insertion process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid and precise application of liners on an industrial scale, enhancing the reuse of containers, reducing waste, and lowering production costs while providing environmental benefits.
Implementation Method 1
utilizing vacuum gripping elements to orient and position liners correctly within the containers
Implementation Method 2
utilizing vacuum gripping elements and expandable membranes to orient and position liners correctly within the containers
Data Source
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AI summary
A method for applying liners (12) inside containers (14), comprising: - providing a plurality of liners (12) each having a bottom wall (16), a side wall (18), an upper opening (20) opposite the bottom wall (16) and a fold (22) extending around the edge of the upper opening (20), - placing said plurality of liners (12) in at least one vertical stack (26) in which the liners (12) are upside down and one inside the other, - pulling the liner (12) at the top of the stack (26) out of the stack (26) in a vertical direction and overturning the liner (12) so as to orient it vertically with the upper opening (20) facing upwards, - inserting a gripping tool (44) into the liner (12) and gripping the liner (12) with said gripping tool (44), - inserting the gripping tool (44) and the liner (12) held thereby inside a container (14) and placing the liner (12) inside the container (14), and - releasing the liner (12) into the container (14) and removing the gripping tool (44) from the container (14) .